Contact Lens Packaging

ABSTRACT

A contact lens package includes a base including an upper surface and a receptacle having a volume. The contact lens package also includes a flexible cover including an interior surface that is coupled to the upper surface of the base. A stiff dome is attached to an interior surface of the cover and the stiff dome displaces an amount of volume from the volume of the receptacle. The contact lens package may also include a lens having an anterior surface and a posterior surface disposed in the receptacle with the posterior surface of the lens disposed adjacent to the stiff dome. By peeling the flexible cover away from the base, the lens remains mounted on the stiff dome causing the anterior surface of the lens to be presented to a user.

FIELD

The present disclosure generally relates to packaging for contact lenses, and more particularly, to contact lens packaging having means for presenting the anterior surface of a contact lens to a user.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Contact lenses are typically contained in disposable packages. For example, contact lenses may be contained in a plastic blister package that includes a receptacle portion for holding the contact lens and a sterile, hydrating solution such as a saline solution. The receptacle, containing the contact lens immersed in the solution, is hermetically sealed, for example, by sealing lid stock on the package over the receptacle. When the lid stock is sealed on the blister, a significant air bubble is present in the blister along with the lens. In use, a user removes the lid stock from the receptacle (e.g., at a flange or tab formed on the blister package) by peeling back the lid stock to expose the lens immersed in the hydrating solution. This package often requires users to search for the contact lens after opening and to reposition the lens on a fingertip in a proper orientation for insertion, such actions often requiring use of a second hand and contact with the posterior surface of the lens, leading to an increased risk of contamination.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

Example embodiments of the present disclosure generally relate to packaging for contact lenses. In one example embodiment, a contact lens package generally includes a base including an upper surface and a receptacle having a volume. The contact lens package also includes a flexible cover including an interior surface that is coupled to the upper surface of the base. A stiff dome is attached to the interior surface of the cover and the stiff dome displaces an amount of volume from the volume of the receptacle. The contact lens package may also include a lens having an anterior surface and a posterior surface disposed in the receptacle with the posterior surface of the lens disposed adjacent to (e.g., contacting) the stiff dome. By peeling the flexible cover away from the base, the lens remains mounted on the stiff dome causing the anterior surface of the lens to be presented to a user.

In another example embodiment, a contact lens package generally includes a first layer including an upper surface and a receptacle having a volume. The receptacle is recessed from the upper surface. The package also includes a second layer that is coupled to the first layer. A hemispherical support is attached to the second layer, the hemispherical support aligned with the receptacle and configured to displace an amount of volume from the volume of the receptacle. The contact lens package may also include a lens having a convex surface and a concave surface disposed in the receptacle with the concave surface of the lens disposed adjacent to (e.g., contacting) the hemispherical support. By peeling the second layer away from the base, the lens remains mounted on the hemispherical support causing the convex surface of the lens to be presented to a user.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an example embodiment of a contact lens package, with the cover removed from the base to show the internal components of the package;

FIG. 2 is a perspective view of the contact lens package of FIG. 1 with the cover coupled to the base; and

FIG. 3 is a rear perspective view of the contact lens package of FIG. 2 .

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments of the present disclosure generally relate to contact lens packages that include means for minimizing and/or eliminating air bubble(s) within the package as well as means for precisely positioning a contact lens within the package, for example, where an anterior surface (e.g., a convex surface) of the contact lens is presented to a user. Contact lens packages commonly include a receptacle for holding a contact lens immersed in a sterile packaging solution, with one or more air bubbles present in the receptacle, where the contact lens is able to move about within the receptacle (e.g., where a user has to search for the lens within the receptacle, etc.). The air bubble(s) may significantly impact the roundness and edge lift (warpage) of the lenses as well as cause the lens to become everted, stuck to the flat lid stock, and/or folded in a corner of the package. In this way, the air bubble(s) create dimensional variability for the lenses where the lenses may not pass dimensional inspection audits during stability testing. Additionally, such contact lens packages, once opened by the user, present the lens concave side up in a concave blister. This orientation makes it impossible for a user to get the lens out of the package and in the proper orientation with a single hand (e.g., one hand initially touches the concave side of the lens to remove the lens from the package and the other hand must touch the opposite side of the lens to reposition the lens into a proper orientation). Greater handling increases the risk that the lens is damaged, contaminated, or mistakenly everted. This effort can result in potential comfort issues, or might require multiple insertion attempts.

Uniquely, the contact lens packages of the present disclosure include a stiff dome that is attached to the lid stock and aligned with the receptacle to displace an amount of the volume within the receptacle, so as to minimize and/or eliminate the presence of air bubbles within the package (e.g., the dome forces air bubbles out of the receptacle). Due to this displacement by the dome, the lens does not evert within the package and remains in proper shape, thereby reducing dimensional variability of the lens. In particular, the dome supports the lens and prevents folding, warpage, and/or eversion of the lens, which enables the lens to retain a more uniform diameter and sagittal depth. Moreover, less saline solution is required within the receptacle due to the presence of the dome. In this way, spillage upon opening of the package may be reduced as well as the risk of misuse by storing the lenses in the packaging solution which is non-sterile after initial opening and removal of the lens. Further, as the dome displaces the amount of volume, the concave (or posterior) side of the lens is adjacent to the curved surface of the dome. When the package is opened, the lens consistently stays with the dome (e.g., the foil side of the package), such that an anterior surface of the lens is presented to the user upon opening of the package. Because the anterior side of the lens is up when the package is opened, a more hygienic transfer of the lens to an eye of the user is possible (e.g., fewer steps are needed to properly orient the lens, a user does not need to touch the posterior surface of the lens to remove the lens from the package, a user may use only a single hand for removal of the lens from the package and insertion of the lens, etc.).

Example embodiments will now be described more fully with reference to the accompanying drawings. The description and specific examples included herein are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

FIGS. 1-3 illustrate an example embodiment of a package 100 for contact lenses including one or more aspects of the present disclosure. In the illustrated embodiment, the package 100 generally includes a base 102 (broadly, a first layer) and a cover 104 (broadly, a second layer) that is coupled to the base 102 to seal a contact lens 106 within the package 100. A stiff dome 108 (broadly, a support) is coupled to the cover 104 and is sealed within the package 100 along with the lens 106.

The base 102 is generally shaped as a blister and includes a receptacle 110 (e.g., basin, well, etc.) that is generally dome-shaped. The receptacle 110 defines a volume for receiving the contact lens 106 and a sterile buffered saline solution (BSS). The base 102 includes an upper surface 112 and the cover 104 is coupled (e.g., heat sealed, etc.) to the upper surface 112 of the base 102. The base 102 is preferably formed to be generally rigid, for example, to prevent damage to the contact lens 106 during transport, shipping, storage, etc. of the package 100. Additionally, the base 102 provides a sturdy grip for a user when peeling (e.g., removing) the cover 104 away from the upper surface 112 of the base 102 to allow access to the lens 106 within the package 100. For example, in some embodiments, the base 102 includes a grip portion 114 (e.g., a textured portion, an opening defined by the base 102, a tab, etc.) to facilitate additional grip for the user when opening the package 100 to remove the lens 106 from the package 100.

The base 102 may be formed of a molded plastic (e.g., thermoformed, injection molded, etc.). For example, the base 102 may be formed of any suitable material such as injection molded or thermoformed plastics for medical packaging including PET (polyethylene terephthalate), PP (polypropylene), HDPE (high density polyethylene), PS (polystyrene), PA (polyamide), etc.; bio-based plastics such as bio-PET, bio-PE/PP and bio-PEF (polyethylene furanoate), etc.; other materials including biodegradable PLA (polylactic acid), PHA (polyhydroxyalkanoate), PBS (polybutylene succinate), cellulose acetate, starch and related compounds; and/or plastic laminated materials including combinations of two or more of the example polymers listed above with requisite binders (e.g., hot melt PE or EVOH), recyclable paper/bio-polymer composites such as paper/PLA or paper/PE laminates, light-weighted options such as microfibrillated cellulose coatings on paper, etc.

In the illustrated embodiment, the cover 104 (e.g., lid stock, etc.) includes an exterior surface 116 (shown in FIG. 2 ) and an interior surface 118. The exterior surface 116 may include indicia thereon pertaining to a prescription of the contact lens 106. In particular, indicia such as the prescription strength of the lens, a lot number, and an expiration date is provided on the exterior surface 116 of the cover 104. In the illustrated embodiment, the dome 108 is attached to the interior surface 118 of the cover 104. The interior surface 118 of the cover 104 is coupled to the upper surface 112 of the base 102 to hermetically seal the dome 108, the lens 106, and the buffered saline solution within the package 100. In particular, the cover 104 may be attached to the base 102 through a heating process (e.g., heat sealed) or other known sealing methods. In some embodiments, the cover 104 includes a tab which extends at least partially beyond the base 102 (e.g., is not coupled to the upper surface 112 of the cover 104) to facilitate opening of the package 100. In particular, a user may remove the cover 104 by peeling the cover 104 away from the base 102 at the tab.

The cover 104 may be a foil material, such as a multilayer laminated foil material. Examples of multilayer laminated foil include polypropylene backed aluminum foil with a thickness of 30 to 300 microns, with a preferred thickness between 20-150 microns. In some embodiments, the aluminum foil is cold rolled from billets and finished by the addition of a seal layer. Seal layer materials may include polypropylene and low & high-density polyethylene and blends thereof. The multilayer laminated foil also includes a topcoat (opposite to the seal layer) that is used for marking, printing, etc. In some embodiments, the multilayer laminated foil for the cover 104 includes a foil made with cold rolled soft aluminum, a polypropylene/LDPE seal layer and polyvinyl butyrate/polyurethane top print layer. For those embodiments, the weight fraction of aluminum with respect to the total laminate is greater than 85%, with the preferred fraction of 90%. The recyclability of such a laminate is enhanced with a greater weight fraction of aluminum as the separation of the seal material from the aluminum can be cumbersome. In some embodiments, the material for the cover 104 may be hydrophilic in nature due to the combination of surface texture and seal layer composition.

In the illustrated embodiment, the dome 108 is hemispherical and is coupled to the interior surface 116 of the cover 104. The dome 108 is positioned such that when the cover 104 is coupled to the base 102, the dome 108 is aligned with the receptacle 110 of the base 102. The outer diameter of the dome 108 is slightly smaller than the outer diameter of the receptacle 110 of the base 102, for example, to enable the entire dome 108 to be positioned within the receptacle 110. This also prevents the dome 108 from interfering with the seal formed between the cover 104 and the base 102. For example, the dome 108 does not form part of the seal between the cover 104 and the base 102. In the illustrated embodiment, the dome 108 is coupled (e.g., sealed) to the cover 104 prior to sealing the cover 104 to the base 102 (e.g., the dome 108 is pre-sealed to the cover 104, etc.). Then, when the cover 104 is coupled (e.g., sealed) to the base 102, the dome 108 displaces an amount of the volume within the receptacle 110. For example, the dome 108 displaces some of the volume within the receptacle 110 to minimize the amount of air that is sealed within the receptacle 110 of the package 100 (e.g., no air bubble is present within the sealed package 100, etc.) compared to a package without a dome. By minimizing air bubbles from the package 100, the dome 108 prevents warpage and/or damage to the lens 106 as well as prevents the lens 106 from being everted within the receptacle 110 (e.g., maintains the lens 106 in the proper orientation and shape, etc.).

Additionally, the dome 108 functions as a stiff, rigid mounting surface for the contact lens 106. Dome 108 is preferably formed of a polymer material that forms a surface for the lens 106 to contact and mate with. Dome 108 is not intended to be easily deformed, bent, or twisted and, as such, dome 108 may be described as stiff, rigid, firm, inelastic, nonpliant, and/or non-deformable. Similar to the base 102, the dome 108 may be formed of a molded plastic or other stiff, rigid material. In particular, the dome 108 may be formed of any material and/or combination of materials described above in connection with base 102. In some embodiments, the base 102 and the dome 108 are formed of the same material. The dome 108 presents a curved, convex surface (e.g., is hemispherical in shape) which generally corresponds to the concave, posterior surface of the contact lens 106. When the cover 104 is coupled to the base 102, the dome 108 displaces an amount of the volume within the receptacle 110 such that the convex surface of the dome 108 is disposed adjacent to the concave surface of the lens 106. In some embodiments, the dome 108 contacts the concave surface of the lens 106. In some embodiments, the dome 108 (e.g., the convex surface of the dome 108) includes surface texturing to enhances the interactions between the lens 106 and the dome 108. Upon opening the package 100, for example, by pulling the cover 104 including the dome 108 away from the base 102, the lens 106 remains disposed on the convex surface of the dome 108. An adhesion phenomenon is created between the lens 106 and the dome 108 due to suction and/or increased contact between the lens 106 and the dome 108 than the lens 106 and the base 102 (e.g., the base 102 is generally flatter than the lens 106 and forms a single point contact, whereas the dome 108 better matches the shape of the lens 106). In this way, the anterior or convex surface of the lens 106 is presented to the user on the cover 104 side of the package 100 (e.g., rather than remaining within the receptacle 110) upon opening the package 100. By precisely positioning the lens 106 such that the anterior surface is presented to the user, the dome 108 provides an efficient and more hygienic presentation of the contact lens 106 for the user (e.g., such that the user does not have to search for the lens, determine the correct orientation of the lens, touch the posterior surface of the lens, etc.).

As shown in FIGS. 2-3 , the dome 108 may be hollow and the cover 104 may be conformed to the shape of the dome 108 (e.g., conformed to the concave surface of the hollow dome 108). In these embodiments, the cover 104 includes a dome portion 120 corresponding to the dome 108 (i.e., the cover 104 is not entirely planar). In some embodiments, the dome portion 120 of the cover 104 is formed at the same time as the dome 108 is sealed to the interior surface 118 of the cover 104. In other embodiments, the dome portion 120 is formed prior to the dome 108 being sealed to the cover 104. In still other embodiments, the cover 104 is planar (e.g., does not include a dome portion 120). In those embodiments, the dome 108 may have a flat surface that is coupled to the cover 104. Alternatively, a hollow dome 108 may be coupled to a planar cover 104. It should be appreciated that either a hollow or solid dome 108 may be coupled to either a planar or non-planar cover 104 without departing from the scope of the present disclosure.

Contact lens packages of the present disclosure include a unique support structure coupled to the interior surface of the lid stock which precisely positions a contact lens within a receptacle of the package, while simultaneously displacing or reducing the volume within the receptacle (e.g., to ensure the lens remains in the proper shape, to prevent the lens from being everted, to reduce the fill volume within the package, etc.). By securing the support structure to an interior surface of the lid stock, the contact lens is able to be easily located within the package in a proper orientation with an anterior surface (e.g., a convex surface) of the contact lens presented to a user. Because the anterior side of the lens is up when the package is opened, a more hygienic transfer of the lens to an eye of the user is possible (e.g., fewer steps are needed to properly orient the lens, a user does not need to touch the posterior surface of the lens to remove the lens from the package, the lens may be removed and inserted with one hand, etc.).

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” as well as the phrase “at least one of” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper”, “lower” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure. 

What is claimed is:
 1. A contact lens package comprising: a base including an upper surface and a receptacle having a volume; a flexible cover including an interior surface, the interior surface coupled to the upper surface of the base; and a stiff dome attached to the interior surface of the cover, wherein the stiff dome displaces an amount of volume from the volume of the receptacle.
 2. The contact lens package of claim 1, further comprising a lens disposed in the receptacle, the lens including an anterior surface and a posterior surface, wherein the posterior surface of the lens is disposed adjacent to the stiff dome.
 3. The contact lens package of claim 2, wherein the contact lens package is configured such that, by peeling the flexible cover away from the base, the lens remains mounted on the stiff dome causing the anterior surface of the lens to be presented to a user.
 4. The contact lens package of claim 1, wherein the stiff dome and the base are formed of the same material.
 5. The contact lens package of claim 1, wherein the flexible cover is a foil material.
 6. The contact lens package of claim 1, wherein the flexible cover is planar.
 7. The contact lens package of claim 1, wherein the stiff dome is hollow.
 8. The contact lens package of claim 7, wherein the flexible cover is conformed to the stiff dome.
 9. A contact lens package comprising: a first layer including an upper surface and a receptacle having a volume, the receptacle recessed from the upper surface; a second layer coupled to the first layer; a hemispherical support attached to the second layer, the hemispherical support aligned with the receptacle and configured to displace an amount of volume from the volume of the receptacle.
 10. The contact lens package of claim 9, wherein a first surface of the second layer is coupled to the first layer and wherein the hemispherical support is attached to the first surface of the second layer.
 11. The contact lens package of claim 9, further comprising a lens disposed in the receptacle, the lens including a convex surface and a concave surface, wherein the concave surface of the lens is disposed adjacent to the hemispherical support.
 12. The contact lens package of claim 11, wherein the contact lens package is configured such that, by peeling the second layer away from the first layer, the lens remains mounted on the hemispherical support causing the convex surface of the lens to be presented to a user.
 13. The contact lens package of claim 9, wherein the hemispherical support and the first layer are formed of the same material.
 14. The contact lens package of claim 9, wherein the second layer is a foil material.
 15. The contact lens package of claim 9, wherein the second layer is planar.
 16. The contact lens package of claim 9, wherein the hemispherical support is hollow.
 17. The contact lens package of claim 16, wherein the second layer is conformed to the hemispherical support. 